System and method of mounting a removable and adjustable photovoltaic ballast frame device

ABSTRACT

A photovoltaic (PV) module mounting system comprises a plurality of PV modules, support brackets disposed under the modules and a ballast frame disposed under and attached to the support brackets. The ballast frame is supported on conventional building rooftops and attached thereto by conventional methods. The support bracket consists of front and rear supports, which can be adjusted to alter the desired tilt angles of the overlying PV modules. The ballast frames can be adjusted to varying widths and lengths. The system is effective in reducing the net effect of wind uplift force when modules are mounted on building rooftops. Additionally, the system provides the advantage of ease of use with less components and minimal roofing penetrations.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to provisionalapplication Ser. No. 60/996,486, filed Nov. 20, 2007, the contents ofwhich are incorporated by reference.

FIELD OF INVENTION

The present invention is directed generally to an apparatus and methodsfor use in a removable or adjustable mounting or assembling photovoltaic(PV) ballast frame system for use on flat surfaces.

BACKGROUND OF INVENTION

Prior art PV module ballast frame structures typically has thedisadvantage of having many parts and multiple penetrations to a roofingstructure upon which it is installed. Accordingly, light weightcomponents, minimal penetration, ease of installation and reduced laborcosts are major concerns of customers in the PV module ballast framemarket. Specifically, the number of penetrating roofing attachments candecrease the effectiveness of expensive roofing surfaces. As a result,there is an increasing need to develop PV mounting frame systems thateliminate or reduce roofing penetration. There is an additionalnecessity to develop a PV mounting system, whereas to ensure that theinstalled system is less susceptible environmental stresses such aswind-loading.

SUMMARY OF INVENTION

The present invention in one embodiment provides a method and apparatusfor mounting solar modules and other flat objects onto a relatively flatsurface. Among the advantages to this embodiment includes that it hasrelatively few components and easy assembly. Further, parts can beconfigured to accommodate a plurality of sizes of flat objects. Thepresent invention can comprise a bracket for maintaining flat objects,e.g. PV solar panels, at a plurality of angles, a ballast frame, whichhas the ability to be secured to a flat surface and bolt and nuthardware for attaching the bracket to the flat object and ballast frame.Additionally, embodiments of the present invention provide for minimalor zero penetrations of the flat surface upon which the system is beingmounted. The minimal or zero penetrations of the flat surface, i.e.,rooftop can be achieved by any fastening technique, including methodssuch as use of nuts, washers and bolts or adhesives. Alternatively, thepresent invention can be installed without the use of any fasteningdevices, wherein weighted objects attached to the ballast frame are usedinstead.

The photovoltaic ballast frame system incorporates horizontal andvertical members, at least one bracket and hardware components to attachthe bracket to at least one member of the ballast frame. The ballastframe system allows for movement of the members to alter theconfiguration of a particular frame or collection of frames.Specifically, multiple frames can be attached to each other, as well asmultiple brackets. Additionally, the ballast frame system can beconstructed to accommodate varying sized or type of weighted objects.Also, the ballast frame system can incorporate grounding means betweenthe plurality of components.

The method for constructing the photovoltaic ballast frame systemincludes constructing a ballast frame system, constructing at least onebracket, attaching the ballast frame to at least one bracket andattaching the ballast frame to a roofing surface. Additionally, themethod includes grounding one or more components of the ballast framesystem. Further, the method can include attaching a weighted object tothe constructed ballast frame.

BRIEF DESCRIPTION OF DRAWINGS

The present invention will be understood and appreciated more fully fromthe following detailed description, taken in conjunction with thedrawings in which:

FIG. 1 is a depiction of a two bay ballast frame;

FIG. 2 is a depiction of a single bay ballast frame;

FIG. 3 is a depiction of a support bracket used to support a PV module;

FIG. 4 is an embodiment of hardware used to attach the support bracketto the ballast frame and flat surface: e.g., a hex bolt, a washer orflange nut;

FIG. 5 is an inverted PV module fastened to a support bracket with aplurality of hardware components;

FIG. 6 is a PV module fastened to a double bay ballast frame;

FIG. 7 is a depiction of the fastening hardware components being used toaffix the support bracket to the double bay ballast frame in FIG. 6;

FIG. 8 is a second PV module and support brackets fastened to a doublebay ballast frame;

FIG. 9 is one PV module and support brackets mounted to a double bayballast frame and a second PV module and support brackets mounted to thefront end of the double bay ballast frame in the rear and a single bayballast frame in the front;

FIG. 10 is two attached columns of PV modules and support bracketsmounted to single bay ballast frames;

FIG. 11 is an exploded view of the connection of two columns of PVmodules mounted to single bay ballast frames;

FIG. 12 is an alternative view of the PV module being connected to twoconnected ballast modules by a plurality of support brackets;

FIG. 13 is an alternative configuration of a non-extended single bayballast frame design;

FIG. 14 is an exploded view of the connection of a plurality ofnon-extended single bay ballast frames; and

FIG. 15 is a 2 by 2 array comprising four modules and six single ballastframes.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

Embodiments consistent with the present invention utilize varyingconfigurations of ballast frames to support PV modules for personal orresidential energy needs. In particular, these ballast frames can beconstructed to accommodate varying sizes of PV modules as well as morethan one frame can be configured to attach to each other. Typically, theballast frames are installed on roofing structures. Accordingly,weighted objects, e.g., concrete blocks, can be placed in ballast framesto combat natural lift forces, which can be created by wind.

FIG. 1 is an exemplary non-limiting embodiment of double bay ballastframe 10. The double bay ballast frame 10 consists of horizontal members1-4 and vertical connection members 5 and 6. Extensions 100 a-d extendvertical connection members 5 and 6 for the purpose of connecting aplurality of ballast frame members. Extensions 100 a and 100 b arecreated by altering the position of horizontal members 1 and 2 withinvertical members 5 and 6. A single bay ballast frame is created byhorizontal members 1 and 2 and an end of 5 and 6. Similarly, anothersingle bay ballast frame is created by horizontal members 3 and 4 andthe opposite end of vertical members 5 and 6. Middle portions 101 a and101 b are shown between the two single bay ballast frames.

Typically, solar panels are positioned to face a southern direction.Therefore, it should be appreciated that “vertical” connection members 5and 6 are generally oriented in a north/south direction; whereas“horizontal” members 1 and 2 are generally positioned in an east/westdirection. Generally, the “vertical” member extends perpendicularly fromthe “horizontal” member. Further, the ballast frame can be oriented suchthat it lies flat or at an angle. See FIG. 6.

The adjustable nature of the present invention can be demonstrated byFIG. 2, which is an embodiment of a single bay ballast frame 20. In thisembodiment, a single row is created by horizontal members 7 and 8,wherein weighted objects can be placed. Horizontal members 7 and 8 areconnected with short vertical members 9 and 10. Extension members 102a-102 d are created within vertical members 9 and 10 by altering theposition of horizontal members 7 and 8. An alternative embodiment of asingle bay ballast frame is provided in FIG. 13.

Referring to FIG. 3, a schematic embodiment of a support bracket 30 usedto support PV module on a flat surface is shown. A portion of supportbracket 30 would be attached to a PV module and the other end wouldattach to a ballast frame as shown in FIG. 1 or 2. The bracket 30comprises a horizontal chamber 14, a front support 16 and a rear support15, which can both be made of folded metal, e.g., aluminum. In analternative embodiment, front and rear supports 16 and 15 respectively,can also consist of a singular angled, e.g., a cylindrical post. Supportmembers 15 and 16 can be attached to horizontal chamber 14 in a varietyof manners including welds or mechanical means such as rivets, adhesive,bolts or other fasteners. If the support members are welded to thehorizontal chamber, welds are executed at end 104 of rear support 15 and103 a and 103 b for front support 16.

FIG. 4 is a non-limiting embodiment of 3 fastening elements, which areused to attach the support bracket 30 to either a PV module or a ballastframe, e.g., FIGS. 1 and 2. These elements consist of a bolt or screw11, a washer 12 and a nut 13. As previously stated, these elements canbe used to attach support members 15 and 16 to horizontal channel 14, orin any other place in the system where fastening is desired.

Referring to FIG. 5, an inverted view is shown of a PV module 19 beingattached to two support brackets 17 and 18. In this embodiment, bolt 11,washer 12 and nut 13 are used to fasten brackets 17 and 18 to PV module19.

As previously stated, a PV module can be attached to a plurality ofconstructed ballast frames. FIG. 6, for example, is an embodiment of aPV module 19 being attached to a double bay ballast frame 10, utilizingsupport brackets 106 a and 106 b attached. As previously described,double bay ballast frame can be comprised of two single bay ballastframes. Also, this embodiment demonstrates the double bay ballast frameattached to a roofing structure 200. The ballast frame 200 can beattached to roofing structure 200 in any desired manner, includingmechanical means, adhesives etc. As shown, roofing surface 200 is arelatively flat surface; however, it should be appreciated that thepresent invention can be utilized in conjunction with any surface uponwhich the present invention can be attached.

In an effort to further depict the attachment of support bracket 106 bto double bay ballast frame 10 in FIG. 6, an exploded view of suchattachment is provided in FIG. 7. In this embodiment, horizontal chamber24 is attached to rear support 25 by use of fastening elements bolt 11,washer 12 and nut 13. Support member 106 b is also attached tohorizontal member 2.

As previously discussed multiple PV modules can be attached to a ballastframe. Accordingly, FIG. 8 is an embodiment of an additional PV modulebeing attached to a double bay ballast frame. PV modules 31 and 33attached to double bay ballast frame 10. Similar to previousembodiments, support brackets 32 a, 32 b are attached to horizontalmember 4. Support bracket 34 is attached to horizontal members 2 and 3.

Multiple PV module columns can be created by attachment of additionalballast frames to PV modules attached to other ballast frames. As shownin FIG. 9, an embodiment of PV module 41 attached to double bay ballastframe 10. Also, in this embodiment an additional PV module 42 isattached to via support brackets 45 and 46 to the front of double bayballast frame 10 and the rear of single bay ballast frame 20. Supportmembers 45 and 46 are attached to horizontal member 8. Additionally, athird PV module could be attached to horizontal member 7 of single bayballast frame 20. Thus, an extended column of alternating PV modules andballast frames can be attached to each other.

Embodiments of the present invention provides for multipleconfigurations or arrays of PV modules. FIG. 10 is an embodiment ofalternating single bay ballast frames 51 and 54 connected to PV modules47 and 50 respectively. In this embodiment, ballast frames 52 and 53 areattached to single bay ballast frames (and the attached PV modules 48and 49 respectively). This configuration shows a 2 by 2 array. FIG. 11is an exploded view of the connection of single bay ballast frames 53and 54. As shown in previous non-limiting embodiments, the connection ofballast frames is made by use of bolt 11, washer 12 and nut 13.

Embodiments of the present invention provide for multiple configurationsof PV module arrays, i.e., 1×2, 2×2 etc. arrays. FIG. 12 is anembodiment of a 1 by 2 array of PV modules 62 a and 62 b. In thisembodiment, support brackets 63 a-d are attached to ballast frames 641a-d.

Embodiments of the present invention also allow for a pluralityconfigurations of ballast frames. For example, FIG. 13 is an alternativeballast frame design for single bay ballast frames 65 a-d. In thisembodiment, extensions are not affixed to vertical members 108 a-d, asshown in FIG. 2. An exploded view of the connection of ballast frames 65c and 65 d is shown in FIG. 14. The frames are attached by bolt 11,washer 12 and nut 13. A grounding washer 67 is also shown between theballast frames 65 c and 65 d. Grounding washer 67, which can be used inany embodiment of the present invention, allows for grounding of onesingle bay ballast frames 65 c and 65 d. Grounding washers can also beused for grounding a PV module to the support bracket or from thesupport bracket to the ballast frame. Grounding washers provide theadvantage of minimizing the number of grounding wires, which wouldotherwise be necessary for each module and frame member. Integration ofgrounding washers provides a continuous ground path throughout a PVarray.

FIG. 15 is a 2 by 2 module array consisting of four PV modules 69 a-dand six single bay ballast frames 70 a-f. In this embodiment, aplurality of ballast blocks 71 are shown, which provides weight tocounterbalance the lift force of wind when the present invention issituated on a flat surface such as a rooftop. An example of ballastblocks are concrete blocks.

While the foregoing describes various embodiments of the presentinvention, those of ordinary skill in the relevant arts will recognizethe many variations, alterations, modifications, substitutions and thelike as are readily possible, especially in light of this description,the accompanying drawings and claims drawn thereto. In any case, becausethe scope of the present invention may be much broader than a particularembodiment, the foregoing detailed description should not be construedas a limitation of the scope of the present invention, which is limitedonly by the claims appended hereto.

1. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object, comprising: a bracket wherein the bracket can be positioned in a plurality of angles; a ballast frame, wherein the ballast frame consist of a plurality of longitudinal and latitudinal members and further wherein a plurality of brackets can be attached; and a hardware system, wherein the bracket can be connected to at least one of the flat object or to the ballast frame.
 2. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein a weighted object can be attached to the ballast frame.
 3. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the hardware system comprises at least one of a bolt, nut or washer.
 4. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein at least a portion of the bracket is mounted to a flat object.
 5. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 3, wherein the flat object is grounded to at least one of the tilt bracket or the ballast frame.
 6. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the weighted object comprises at least one concrete block.
 7. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the members are arranged in a plurality configurations.
 8. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the members comprises at least one of a longitudinal or latitudinal member.
 9. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the bracket comprises a channel and further wherein the channel is made of aluminum or other material such as steel, wood or plastic.
 10. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein a metallic substance is affixed to the channel by at least one of welding, a rivet, an adhesive or a bolt.
 11. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 7, wherein a metallic substance is affixed to at least one end of the channel by at least one of welding, a rivet, an adhesive or a bolt.
 12. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the ballast frame comprises holes in which the bracket can be attached.
 13. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 8, wherein the longitudinal and latitudinal members are assembled into a rectangular configuration.
 14. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 13, wherein the members are configured to support a plurality of sizes of weighted objects.
 15. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 13, wherein the rectangular configuration is dimensioned to house a plurality of concrete blocks.
 16. A method of installing a photovoltaic module or flat panel on an object comprising the steps of: constructing a ballast frame; attaching a ballast frame to a plurality of brackets; attaching the ballast frame affixed to the brackets to a surface.
 17. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein at least one weighted object is inserted into the ballast frame to weight the photovoltaic system to the flat surface.
 18. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein the brackets are attached to the ballast frame by at least one of a hex bolt, a washer or a flange nut.
 19. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein the ballast frame affixed to the flat surface is attached by at least one of a hex bolt, a washer or a flange nut.
 20. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein a grounding washer is inserted between more than one constructed ballast frames. 